Muffler system with pneumatically actuated bypass valve

ABSTRACT

A device may include a first pipe and a second pipe defining a first and second flow path through a muffler body. The second pipe is a muffled flow path and includes a plurality of perforations configured to allow exhaust gasses flowing therethrough to disperse out of the second pipe and into an interior volume of the muffler body. A device may include a valve disposed in the first flow path, wherein when the valve is in an open position exhaust gases flow through the first flow path and when the valve is in a closed position exhaust gases flow through the second flow path. A device may include a controller configured to selectively cause the valve to transition from the open position to the closed position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and incorporates by reference U.S.Provisional Patent Application No. 63/342,747 entitled “MUFFLER SYSTEMWITH PNEUMATICALLY ACTUATED BYPASS VALVE” and filed on May 17, 2023.

TECHNICAL FIELD

The subject invention relates to a pneumatically actuated valve systemof a muffler of a vehicle exhaust system, and, more particularly, to apneumatically actuated valve system enabling components of a vehicle'smuffler system to be selectively bypassed.

BACKGROUND OF THE INVENTION

Exhaust systems are widely known and used with combustion engines.Typically, an exhaust system includes exhaust pipes that convey exhaustgases from the engine to other exhaust system components, such asmufflers, etc. Conventional exhaust mufflers include acoustic chambersand baffling that are configured to work together to cancel out soundwaves carried by the exhaust gases. In performing this function,however, mufflers can reduce engine performance and artificially modifythe true sound of the vehicle's engine and exhaust.

BRIEF DESCRIPTION OF THE FIGURES

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 depicts an automotive vehicle.

FIG. 2 depicts a muffler control system of the present disclosure.

FIGS. 3A-3D are photographs showing various views of a muffler.

FIG. 4 is a photograph depicting an example vacuum pump.

FIG. 5 is a photograph depicting a muffler control system.

FIGS. 6A-6D are photographs showing various views of a muffler.

FIG. 7A-7C depict an embodiment of a muffler configured in accordancewith the present disclosure.

DETAILED DESCRIPTION

The following description recites various aspects and embodiments of theinvention disclosed herein. No particular embodiment is intended todefine the scope of the invention. Rather, the embodiments providenon-limiting examples of various configurations, and methods that areincluded within the scope of the claimed invention. The description isto be read from the perspective of one of ordinary skill in the art.Therefore, information that is well known to the ordinarily skilledartisan is not necessarily included.

Referring now to the drawings, like reference numerals are used toidentify identical components in the various views. Referring to FIG. 1, an automotive vehicle 100 is shown. Vehicle 100 includes an internalcombustion engine 102 coupled to an exhaust system 104 in accordancewith the present invention.

Engine 102 includes an exhaust manifold coupled to exhaust system 104.Exhaust gas generated by engine 102 passes through exhaust system 104 toan exhaust pipe outlet. Such gases pass through exhaust system 104 atrelatively high and varying pressures and generate acoustic signalsthroughout exhaust system 104 and at the output of exhaust system 104.

In a typical automotive vehicle 100, exhaust system 104 includes amuffler 106. Muffler 106 is configured to control the flow of exhaustgases through exhaust system 104 to moderate the volume of soundsgenerated by exhaust system 104. In many implementations, by interferingwith exhaust flow through exhaust system 104, a muffler 106 can impedethe normal operation of the engine 102 of automotive vehicle 100,sometimes resulting in reduced power output of engine 102. In othercases, the muffler 106 will not only reduce the overall volume of soundsgenerated by the exhaust gases passing through exhaust system 104, butwill also change those sounds so as to affect the overall timbre orsound quality of the exhaust system 104.

Although the volume reductions that result from conventional muffler 106operation can be beneficial to some driving environments (e.g., such aswhen navigating a local neighborhood, or driving late at night), muffler106 operations can sometimes be undesirable as they can preventefficient operation of engine 102 and may also interfere withappreciation of the true sound of the vehicle's engine 102.

The present system, therefore, provides an improved muffler design inwhich the muffler includes first and second exhaust gas flow paths. Whenthe exhaust gases flow through the first path, the muffler providesdampening of acoustic energy within the exhaust gases to reduce theoverall volume of sound generated by an attached exhaust system.However, when the exhaust gases flow through the second path of themuffler, the muffler does not impede the flow of exhaust gases and doesnot provide any (or only minimal) acoustic dampening. Accordingly, whenthe exhaust gases flow through the second path, the originalunadulterated engine noises will flow through and emanate from thevehicle's exhaust system.

To control the operation of the improved muffler, a controllable valveis disposed within the flow path of exhaust gases. When the valve is ina first position, the second flow path is closed and exhaust gases areforced through the first, muffled, flow path. However, when the gate isopen (or vice versa), the uninhibited exhaust gases are free to flowthrough the second flow path to generate an unmuffled exhaust output.

In an embodiment, the valve is pneumatically operated and, specifically,the valve may be vacuum-driven. In that case, in a default position(e.g., when no vacuum is applied to the valve) the valve is closed andcauses the muffler to operate to reduce exhaust volume. However, when avacuum is applied to the valve's control port, the valve opens andallows exhaust gases to flow through the second flow path.

Although the valve could be operated electro-mechanically, such valvesincrease unneeded complexity over vacuum-controlled valves, which may beundesirable in an automotive application. For example,electro-mechanically controlled valves can have reliability issues, haveissues that are difficult to diagnose, and include small, delicatecomponents that are prone to breaking. Vacuum-controlled valves, incontrast, include fewer parts, are more robust, and are easier todiagnose and repair.

Although engines generate vacuum due to normal operation it can bedifficult to route a vacuum hose all the way from the vehicle's enginecompartment to the exhaust system and, specifically, the muffler of theexhaust system. Accordingly, in embodiments, the present system mayinclude a separate vacuum pump that is configured to generate anadequate vacuum that can be selectively applied to the valve to controlthe valve position. The separate vacuum pump can be located anywherewithin the vehicle (e.g., within the trunk or boot of the vehicle,mounted under the chassis or within the chassis of the vehicle) toprovide convenient placement proximate to the vacuum-controlled valve.The vacuum pump can be electrically powered via any suitable means, suchas via a direct electrical connection to the vehicle's battery, viasuitable coupling to a vehicle's cigarette lighter power, via connectionto a separate battery system, and the like.

In some embodiments, to open the valve, the vacuum pump is turned on todeliver an appropriate vacuum to the valve's control port to cause thevalve to open (allowing by-pass of portions of the muffler). To closethe valve, the vacuum pump is turned on or disabled to remove the vacuumto the valve's control port allowing the valve to close.

In various embodiments of the present system, the operation of thevacuum pump is controlled by a controller. The controller may includeswitches or buttons configured to control particular vacuum pumpoperations. The controller may be hardwired to the vacuum pump or may bewireless, in which case the controller may be a key fob-type device.

FIG. 2 depicts a muffler control system 200 of the present disclosure.System 200 includes a muffler 202 that includes gas flow path 204 andgas flow path 206. Flow path 204 includes a main non-muffled flow paththrough muffler 202 and has input 201 and output 203. Flow path 206 is amuffled flow path through muffler 202. Gas flow path 206 includesexhaust pipes that branch from a side of the pipe making up flow path204 of muffler 202. Specifically, gas flow path 206 follows a circuitousroute through the main body of muffler 202. As shown in FIG. 2 ,portions of gas flow path 206 may be perforated (e.g., the portion gasflow path 206 that is disposed within the body of muffler 202) to allowexhaust gases to leak out of gas flow path 206 as they flow through gasflow path 206. The interior volume of muffler 202 (e.g., outside of flowpaths 204, 206) may include a baffling material (e.g., fiberglass orother suitable materials) configured to muffle sounds generated by theexhaust gases that leak out of the perforations of gas flow path 206.

Muffler control system 200 includes valve 210 disposed within flow path204. As illustrated, valve 210 is located within flow path 204 at apoint in the exhaust gas flow between the point where gas flow path 206branches away from flow path 204 and the point where gas flow path 206returns to flow path 204. When valve 210 is closed, flow path 204 isbypassed and exhaust gases flowing from input 201 to output 203 isforced through path gas flow path 206 towards output 203. As such, whenvalve 210 is closed, the muffler operates to reduce volume and noisebeing generated by exhaust gases flowing through gas flow path 206.

In the present system, valve 210 has an optimized valve body that can becomputer numerical control (CNC) casted. Valve 210 is designed with aneasily replaceable bladder design enabling the valve bladder to beeasily replaced if the valve bladder should ever fail. Specifically,valve 210 has been optimized using a cast design the ensure highquality. Within valve 210, a three-stud design allows the vacuum bladderto be swapped out in a short amount of time. In an embodiment, the shaftmechanism is designed to provide 5 pounds of negative pressure tooperate and therefore a 6-pound threshold on the vacuum bladder isprovided enabling the control box to allow for proper operation of thevalve. Specifically, the present control system is aware of when thevalve is opened or closed depending on the pressure throughout the valvecontrol system.

When valve 210 is open, however, exhaust gases pass directly from hasinput 201 to output 203 through flow path 204. This results in a“straight pipe” exhaust configuration in which exhaust noise generatedby exhaust gases passing through flow path 204 is not diminished bymuffler 202 and the vehicle engine can run at improved efficiency.

As shown in FIG. 2 , the operation of valve 210 is controlled by vacuumpump 212, which is configured to selectively apply sufficient vacuum tovalve 210 to cause valve 210 to modulate between open and closedconfigurations. Ultimately, the operation of vacuum pump 212 iscontrolled by controller 214, which may be used by an operator of thevehicle in which muffler control system 200 is installed to control theposition of valve 210 and overall muffler 202 operation.

In a specific embodiment, vacuum pump 212 may include a robust vacuumpump design to improve reliability and longevity. Vacuum pump 212 mayincorporate an automated sensor that senses when the valve is fullyopened at an appropriate vacuum (e.g., −6 pounds per square inch (PSI)).Once the target vacuum threshold is achieved, vacuum pump 212 may beconfigured to halt generation of further vacuum and hold or maintainvacuum pump 212 in an open position.

Vacuum pump 212 (or other components of muffler control system 200) maybe configured to periodically check (e.g., every 100 millisecond, every1 second, or every 10 seconds) to confirm that vacuum pump 212 isholding at the desired vacuum level (e.g., at 6 PSI with a 0.5 PSImargin). If vacuum pump 212 (or other components of muffler controlsystem 200) upon performing such a periodic check determines that thevacuum pressure generated by vacuum pump 212 has fallen below thedesired vacuum level (or falls below some other threshold), vacuum pump212 may operate to restore the vacuum to the desired vacuum level. Invarious embodiments, an electrical connection may be formed betweenvacuum pump 212 (or other components of muffler control system 200) anda vehicle's onboard diagnostic port (e.g., an OBDII port) to provideenhanced control thereof. For example, using such a connection, mufflercontrol system 200 may be configured to control the operation of vacuumpump 212 and/or valve 210 to achieve a desired operation of muffler 202.

Specifically, in an embodiment, engine speed data (e.g., revolutions perminute (RPM)) may be transmitted from the OBD port to controller 214 andcontroller 214 could use the RPM data as a factor in how controller 214controls the operation of vacuum pump 212 and valve 210. For example, ifthe engine speed falls below a particular threshold, controller 214 mayoperate vacuum pump 212 and valve 210 to close valve 210 to enablemuffled operation of the exhaust (e.g., with exhaust flow through gasflow path 206). If, however, the engine speed exceeds the threshold,controller 214 may operate vacuum pump 212 and valve 210 to open valve210 to enable non-muffled operation of the exhaust (e.g., with exhaustflow through flow path 204. In some embodiments, controller 214 may beconfigured to implement a control algorithm so that the status of valve210 does not continue to oscillation between opened and closed positionsif drive revs fall below the threshold, even momentarily. For example,controller 214 may be programmed so that the valve will only open if therevs exceed the threshold for a percentage of a given time period. Forexample, controller 214 may open the valve 210 if the engine speedexceeds the threshold for 75% of the last 5 minutes. Conversely, oncevalve 210 has been opened, controller 214 may only again close valve 210when the engine speed falls below the threshold for 75% of the last 5minutes. In this manner, momentary changes in engine speed won't causethe valve position to change (e.g., a moment of low revs when breakingin a race condition won't cause the valve 210 to close and a moment ofhigh revs when driving slowly through a neighborhood won't cause thevalve 210 to open.

Similarly, vehicle speed could be used as an input to controller 214 tocontrol valve 210 position. For example, when the vehicle exceeds aparticular valve-open speed threshold (e.g., over 75 mph), the valve 210may be opened, however when the vehicle is traveling less than avalve-closed speed threshold (e.g., 40 mph) valve 210 may be closed.

In this manner, muffler control system 200 may be used to controlvehicle noise in densely populated areas or noise restricted areasallowing for the driver of the vehicle to keep the valves closed until acertain RPM, throttle position, and/or speed is achieved. Inembodiments, controller 214 may be connected to a location system (e.g.,GPS) allowing for control of valve 210 position based upon a location ofthe vehicle.

In various embodiments of muffler 202, the interior diameter of flowpath 204 (designated I_(diam_204) in FIG. 2 ) may be the same orapproximately the same as the interior diameter of 206 (designatedI_(diam_206) in FIG. 2 ). As a consequence of flow path 204 and gas flowpath 206 generally exhibiting the same inner diameter through thelengths of flow path 204 and gas flow path 206, the present muffler 202design may reduce the performance impacts of switch between flow path204 and gas flow path 206 during vehicle operation. Restrictions in theinner diameter size of gas flow path 206 can be a way to lose power andcompromise performance when valve 210 is closed. The present muffler 202design does not exhibit a pipe diameter reduction in order to minimizesound.

Instead, as illustrated in FIG. 2 , the piping of gas flow path 206includes an elbow structure with integrated perforations that utilizesthe same diameter as the muffler bypass flow path 204 but allows for asignificant sound reduction.

Typically, muffler control system 200 may be implemented so that valve210 has a default position of being closed. This implementation canalleviate aggressive cold start functionality of some vehicles. If anypart of muffler control system 200 should break or become non-functionalvalve 210 will automatically close and the vehicle will be able tooperate in a quiet/stock mode until the problem is repaired. It may bepreferable that muffler control system 200 operate as a ‘stock’ muffler,rather than be stuck in a loud mode.

In muffler control system 200 of FIG. 2 , the exhaust gas is depicted asflowing in a particular direction (e.g., as viewed in FIG. 2 , fromleft-to-right), however it should be apparent that the system couldoperated in reverse in which gas flow is generally from right-to-leftand output 203 is in fact an input to the system, while input 201operates as an output. This reversible characteristics is true of thevarious muffler systems described herein (e.g., including muffler 300,muffler 502, muffler 600, and muffler 700).

FIGS. 3A-3D are photographs showing various views of a muffler 300(e.g., muffler 202 of muffler control system 200). A portion of the bodyof muffler 300 includes a cut-out portion 399 (FIG. 3A) allowing a viewof the interior volume of muffler 300. Additionally, to provide a clearview of the interior components of muffler 300, muffler 300 does notinclude any baffling material that would ordinarily be disposed withinthe interior of the body of muffler 300 (while remaining outside of theexhaust paths of muffler 300) to provide enhanced sound dampening.

Muffler 300 includes an input 301 (e.g., input 201, FIG. 2 ) and anoutput 303 (e.g., output 203 of FIG. 2 ). A first flow path 304 (e.g.,flow path 204 of FIG. 2 ) is connected between 301 and 303. A secondflow path 306 (e.g., gas flow path 206 of FIG. 2 ) is connected to firstflow path 304. As depicted in FIGS. 3A-3D, second flow path 306 may beperforated (e.g., the portion gas flow path 306 that is disposed withinthe body of muffler 300) to allow exhaust gases to leak out of gas flowpath 306 as they flow through gas flow path 306. The interior volume ofmuffler 300 may include a baffling material configured to muffled soundsgenerated by the exhaust gases that leak out of the perforations of gasflow path 306.

Muffler 300 includes a control valve 310 (e.g., valve 210 of FIG. 2 ).Control valve 310 may be vacuum controlled between a first position anda second position. In a first, default, position control valve 310blocks the flow of exhaust gas through first flow path 304 and insteadforces the exhaust gas flow through the muffled gas flow path 306.However, when control valve 310 is put into its second position (e.g.,via application of a vacuum), gas flow path 306 is blocked and exhaustgases can flow directly through first flow path 304.

As shown in FIGS. 3A-3D, the body of muffler 300 may have a generallyoval shape. This configuration can provide that muffler 300 can fitunder a wider array of acceptable vehicles. In contrast, other mufflerbodies may be large and bulky.

FIG. 4 is a photograph depicting an example vacuum pump 400 (e.g.,vacuum pump 212 of FIG. 2 ).

FIG. 5 is a photograph depicting a muffler control system 500 (e.g.,muffler control system 200 of FIG. 2 ). Muffler control system 500includes a muffler 502 (e.g., muffler 300 or FIGS. 3A-3D of muffler 202of FIG. 2 ) with control valve 510 (e.g., control valve 310 of FIGS.3A-3D or valve 210 of FIG. 2 ). Muffler control system 500 includesvacuum pump 512 (e.g., vacuum pump 212 of FIG. 2 ) connected to controlvalve 510 via a vacuum line. Vacuum pump 512 is configured toselectively apply a vacuum to control the operation (i.e., between afirst position and a second position) of control valve 510.

A key fob controller 520 may be in wireless communication with vacuumpump 512 to control the operation thereof. By selecting a first userinput on key fob controller 520 a user can cause vacuum pump 512 to putcontrol valve 510 into the first position. By selecting a second userinput on key fob controller 520 the user can cause vacuum pump 512 toput control valve 510 into the second position.

In various embodiments, key fob controller 520 may be a 3D printed keyfob with a distinctive and unique visual design. Portions of key fobcontroller 520 may be 3D printed out of metal to provide a solid robustfeeling to key fob controller 520.

FIGS. 6A-6D are photographs showing various views of a muffler 600(e.g., muffler 202 of muffler control system 200, muffler 300). Aportion of the body of muffler 600 includes cut-out portions 699 (FIG.6A) allowing a view of the interior volume of muffler 600. Additionally,to provide a clear view of the interior components of muffler 600,muffler 600 does not include any baffling material that would ordinarilybe disposed within the interior of the body of muffler 600 (whileremaining outside of the exhaust paths of muffler 600) to provideenhanced sound dampening.

Muffler 600 includes an input 601 (e.g., input 201, FIG. 2 ) and anoutput 603 (e.g., output 203 of FIG. 2 ). A first flow path 604 (e.g.,flow path 204 of FIG. 2 ) is connected between input 601 and output 603.A second flow path 606 (e.g., gas flow path 206 of FIG. 2 ) is connectedto first flow path 604. As depicted in FIGS. 6A-6D, a portion of secondflow path 606 may be perforated (e.g., the portion gas flow path 606that is disposed within the body of muffler 600) to allow exhaust gasesto leak out of gas flow path 606 as they flow through gas flow path 606.The interior volume of muffler 600 may include a baffling materialconfigured to muffled sounds generated by the exhaust gases that leakout of the perforations of gas flow path 606.

In the depicted embodiment, gas flow path 606 includes a 90-degree elbowconfiguration 607. The elbow shape of gas flow path 606 within muffler600 is configured to ensure proper exhaust flow when re-entering themain pathway of the exhaust. Specifically, the 90-degree elbowconfiguration provides for a smoother flow of exhaust gases through gasflow path 606 as compared to exhaust flow paths having U-bends or otherconvoluted shapes, such as gas flow path 306 of muffler 300). In thisconfiguration, the proximal end 650 (e.g., the input end) of the pipe offlow path 604 and the proximal end 652 (e.g., the input end) of the pipeof flow path 606 are parallel to one another, while the distal end 654(e.g., the output end) of the pipe of flow path 604 and the distal end656 (e.g., the output end) of the pipe of flow path 606 are orthogonalto one another.

Additionally, within muffler 600 the diameter of the piping making upfirst flow path 604 is generally equal (or at least approximately equalto) the diameter of the piping making up gas flow path 606. Thisconsistent sizing may allow for muffler 600 to generate a more pleasingsound, even when control valve 610 is closed and exhaust gasses areflowing through gas flow path 606. In some embodiment of muffler 600, inwhich the muffled exhausted flow path has a diameter that issignificantly reduced as compared to the diameter of the non-muffledpath, exhaust flow through the narrow, muffled path can sometimes resultin excessive and unpleasant noise resulting from the necessary increasein exhaust gas velocity as it passes through the narrow exhaust flowpath.

Muffler 600 includes a control valve 610 (e.g., valve 210 of FIG. 2 ).Control valve 610 may be vacuum controlled between a first position anda second position. In a first, default, position control valve 610blocks the flow of exhaust gas through first flow path 604 and insteadforces the exhaust gas flow through the muffled gas flow path 606.However, when control valve 610 is put into its second position (e.g.,via application of a vacuum), exhaust gases can flow directly throughfirst flow path 604.

As shown in FIGS. 6A-6D, the body of muffler 600 may have a generallyoval shape. This configuration can provide that muffler 600 can fitunder a wider array of acceptable vehicles. In contrast, other mufflerbodies may be large and bulky.

FIG. 7A-7C depict a muffler 700 configured in accordance with thepresent disclosure. Muffler 700 includes a muffler body 702. FIG. 7Adepicts an external view of muffler 700. FIG. 7B depicts across-sectional view of muffler 700. FIG. 7C depicts a partiallyexploded view of muffler 700 showing a subset of the internal componentsof muffler 700 with muffler body 702 removed.

Muffler 700 includes an input 701 (e.g., input 201, FIG. 2 ) and anoutput 703 (e.g., output 203 of FIG. 2 ) (in other embodiments, muffler700 may operate in reverse in which the roles of input 701 and output703 are reversed). A first pipe 751 defining a first flow path 704(e.g., flow path 204 of FIG. 2 ) is connected between input 701 andoutput 703. A second flow path 706 (e.g., gas flow path 206 of FIG. 2 )is connected to first flow path 704.

Second flow path 706 is made up of a number of connected volumes.Specifically, muffler body 702 includes internal baffle 753 and internalbaffle 755. Internal baffle 753 extends across the interior of mufflerbody 702 to define end volume 757. Internal baffle 755 extends acrossthe interior of muffler body 702 to define end volume 759. A centralvolume 781 is defined by and between internal baffle 753 and internalbaffle 755. This design ensures the exhaust gases spent reasonable timeinside the muffler, slowing down the gasses' velocity, reducing drone,and ensuring a quiet sound experience.

Second flow path 706 includes pipe 783 that extends from internal baffle753, through internal baffle 755 and to muffler body 702. Second flowpath 706 includes pipe 785 that extends between internal baffle 753 andinternal baffle 755. As illustrated in FIG. 7C, pipe 785 may include twoor more pipes that extend in parallel between internal baffle 753 andinternal baffle 755.

In this configuration, the second flow path 706 extends from port 787into end volume 759, through pipe 785, end volume 757, and pipe 783(and, optionally, pipe 789) at which point the flow path exits mufflerbody 702.

As illustrated in FIG. 7C, a portion of second flow path 706 (includinginternal baffle 753, internal baffle 755, pipe 785, pipe 783, and(optional) pipe 789) may be perforated (e.g., the portion gas flow path706 that is disposed within the body of muffler 700) to allow exhaustgases to leak out of gas flow path 706 as they flow through gas flowpath 706. In that perforated correction, exhaust gases can flow out ofgas flow path 706 and into the central volume 781 of muffler body 702.The central volume 781 (and other volumes of muffler body 702) mayinclude a baffling material configured to muffle sounds generated by theexhaust gases that leak out of the perforations of gas flow path 706.

In a specific embodiment, a diameter 791 of pipe 751 is approximately 76millimeters (mm). A diameter 793 of pipe 783 is approximately 60 mm anda diameter 795 of pipe 785 (and optional pipe 789) is approximately 25mm. In such an embodiment, a length of pipe 751, pipe 783, pipe 785 andoptional pipe 789 may be about 100 mm.

Muffler 700 includes a control valve 710 (e.g., valve 210 of FIG. 2 ).Control valve 710 may be vacuum controlled between a first position anda second position. In a first, default, position control valve 710blocks the flow of exhaust gas through first flow path 704 and insteadforces the exhaust gas flow through the muffled gas flow path 706.However, when control valve 710 is put into its second position (e.g.,via application of a vacuum), exhaust gases can flow directly throughfirst flow path 704, which is an unmuffled exhaust flow path.

In various embodiments, muffler 700 may be configured in multipledifferent sizes in order to fit multiple Vehicles, including 2.5 inch/63mm, 3.0 inch/76 mm, and 3.5 inch/89 mm configurations.

The various mufflers described herein may include short extensions orstubs on the pipes entering and exiting the respective muffler bodies tofacilitate installation in a vehicle by welding.

In some aspects, the techniques described herein relate to a system,including: a muffler body, including: a first pipe defining a first flowpath through the muffler body, wherein the first flow path is anon-muffled flow path, and a second pipe defining a second flow paththrough the muffler body, wherein the second pipe is a muffled flow pathand includes a plurality of perforations configured to allow exhaustgasses flowing therethrough to disperse out of the second pipe and intoan interior volume of the muffler body, wherein the second pipe includesa 90-degree elbow, and a first end of the first pipe and a first end ofthe second pipe are in parallel and a second end of the first pipe and asecond end of the second pipe are orthogonal; a valve disposed in thefirst flow path, wherein when the valve is in an open position exhaustgases flow through the first flow path and when the valve is in a closedposition exhaust gases flow through the second flow path; and acontroller configured to selectively cause the valve to transition fromthe open position to the closed position.

In some aspects, the techniques described herein relate to a system,further including a baffling material disposed into the interior volumeof the muffler body outside the first pipe and the second pipe.

In some aspects, the techniques described herein relate to a system,wherein the controller is a remote controller enabling a user to controla position of the valve wirelessly.

In some aspects, the techniques described herein relate to a system,wherein a diameter of the first pipe is equal to a diameter of thesecond pipe.

In some aspects, the techniques described herein relate to a system,wherein the valve is vacuum operated and further including a vacuum pumpconnected to the valve, wherein the controller is configured to controlan operation of a vacuum pump to cause the valve to transition from theopen position to the closed position.

In some aspects, the techniques described herein relate to a system,wherein an output of the second pipe is in fluid connection with thefirst pipe within the muffler body.

In some aspects, the techniques described herein relate to a system,including: a muffler body, including: a first internal baffle, a secondinternal baffle, wherein the first internal baffle defines a first endvolume between the first internal baffle and the muffler body, thesecond internal baffle defines a second end volume between the secondinternal baffle and the muffler body, and the first internal baffle andthe second internal baffle define a central volume between the first endvolume and the second end volume, a first pipe defining a first flowpath through the muffler body, wherein the first flow path is anon-muffled flow path, a second pipe extending between the firstinternal baffle and the second internal baffle, a third pipe extendingbetween the first internal baffle and the second internal baffle, and asecond flow path defined through the muffler body, wherein the secondflow path extends through the second pipe, the first end volume, thethird pipe, and the second end volume, the second flow path is a muffledflow path and at least one of the second pipe and the third pipeincludes a plurality of perforations configured to allow exhaust gassesflowing therethrough to disperse out of the at least one of the secondpipe and the third pipe and into the central volume of the muffler body;a valve disposed in the first flow path, wherein when the valve is in anopen position exhaust gases flow through the first flow path and whenthe valve is in a closed position exhaust gases flow through the secondflow path; and a controller configured to selectively cause the valve totransition from the open position to the closed position.

In some aspects, the techniques described herein relate to a system,further including a fourth pipe extending between the first internalbaffle and the second internal baffle, wherein the second flow pathincludes the fourth pipe.

In some aspects, the techniques described herein relate to a system,further including a baffling material disposed in the central volume andoutside the first pipe, the second pipe, and the third pipe.

In some aspects, the techniques described herein relate to a system,wherein the first internal baffle includes perforations configured toallow exhaust gasses flowing through the first end volume to disperseout of the first end volume and into the central volume of the mufflerbody.

In some aspects, the techniques described herein relate to a system,wherein the second internal baffle includes perforations configured toallow exhaust gasses flowing through the second end volume to disperseout of the second end volume and into the central volume of the mufflerbody.

In some aspects, the techniques described herein relate to a system,wherein a diameter of the second pipe is from 70 percent to 80 percentof a diameter of the first pipe and a diameter of the third pipe is from30 percent to 50 percent of the diameter of the second pipe.

In some aspects, the techniques described herein relate to a system,wherein a distance between the first internal baffle and the secondinternal baffle is between 120 percent and 140 percent of the diameterof the first pipe.

In some aspects, the techniques described herein relate to a system,wherein the valve is vacuum operated and further including a vacuum pumpconnected to the valve, wherein the controller is configured to controlan operation of a vacuum pump to cause the valve to transition from theopen position to the closed position.

In some aspects, the techniques described herein relate to a muffler,including: a muffler body; a first internal baffle disposed within themuffler body; a second internal baffle disposed within the muffler body,wherein the first internal baffle defines a first end volume between thefirst internal baffle and the muffler body, the second internal baffledefines a second end volume between the second internal baffle and themuffler body, and the first internal baffle and the second internalbaffle define a central volume between the first end volume and thesecond end volume; a first pipe defining a first flow path through themuffler body, wherein the first flow path is a non-muffled flow path; asecond pipe extending between the first internal baffle and the secondinternal baffle; a third pipe extending between the first internalbaffle and the second internal baffle; and a second flow path definedthrough the muffler body, wherein the second flow path extends throughthe second pipe, the first end volume, the third pipe, and the secondend volume, the second flow path is a muffled flow path and at least oneof the second pipe and the third pipe includes a plurality ofperforations configured to allow exhaust gasses flowing therethrough todisperse out of the at least one of the second pipe and the third pipeand into the central volume of the muffler body.

In some aspects, the techniques described herein relate to a muffler,further including a fourth pipe extending between the first internalbaffle and the second internal baffle, wherein the second flow pathincludes the fourth pipe.

In some aspects, the techniques described herein relate to a muffler,further including a baffling material disposed in the central volume andoutside the first pipe, the second pipe, and the third pipe.

In some aspects, the techniques described herein relate to a muffler,wherein the first internal baffle includes perforations configured toallow exhaust gasses flowing through the first end volume to disperseout of the first end volume and into the central volume of the mufflerbody.

In some aspects, the techniques described herein relate to a muffler,wherein the second internal baffle includes perforations configured toallow exhaust gasses flowing through the second end volume to disperseout of the second end volume and into the central volume of the mufflerbody.

In some aspects, the techniques described herein relate to a muffler,wherein a diameter of the second pipe is from 70 percent to 80 percentof a diameter of the first pipe and a diameter of the third pipe is from30 percent to 50 percent of the diameter of the second pipe.

Although the invention(s) is/are described herein with reference tospecific embodiments, various modifications and changes can be madewithout departing from the scope of the present invention(s), as setforth in the claims below. Accordingly, the specification and figuresare to be regarded in an illustrative rather than a restrictive sense,and all such modifications are intended to be included within the scopeof the present invention(s). Any benefits, advantages, or solutions toproblems that are described herein with regard to specific embodimentsare not intended to be construed as a critical, required, or essentialfeature or element of any or all the claims.

Unless stated otherwise, terms such as “first” and “second” are used toarbitrarily distinguish between the elements such terms describe. Thus,these terms are not necessarily intended to indicate temporal or otherprioritization of such elements. The term “coupled” is defined asconnected, although not necessarily directly, and not necessarilymechanically. The terms “a” and “an” are defined as one or more unlessstated otherwise. The terms “comprise” and any form of comprise, such as“comprises” and “comprising”), “have” (and any form of have, such as“has” and “having”), “include” (and any form of include, such as“includes” and “including”) and “contain” (and any form of contain, suchas “contains” and “containing”) are open-ended linking verbs. As aresult, a system, device, or apparatus that “comprises,” “has,”“includes” or “contains” one or more elements possesses those one ormore elements but is not limited to possessing only those one or moreelements. Similarly, a method or process that “comprises,” “has,”“includes” or “contains” one or more operations possesses those one ormore operations but is not limited to possessing only those one or moreoperations.

1. A system, comprising: a muffler body, including: a first pipedefining a first flow path through the muffler body, wherein the firstflow path is a non-muffled flow path, and a second pipe defining asecond flow path through the muffler body, wherein the second pipe is amuffled flow path and includes a plurality of perforations configured toallow exhaust gasses flowing therethrough to disperse out of the secondpipe and into an interior volume of the muffler body, wherein the secondpipe includes a 90-degree elbow, and a first end of the first pipe and afirst end of the second pipe are in parallel and a second end of thefirst pipe and a second end of the second pipe are orthogonal; a valvedisposed in the first flow path, wherein when the valve is in an openposition exhaust gases flow through the first flow path and when thevalve is in a closed position exhaust gases flow through the second flowpath; and a controller configured to selectively cause the valve totransition from the open position to the closed position.
 2. The systemof claim 1, further comprising a baffling material disposed into theinterior volume of the muffler body outside the first pipe and thesecond pipe.
 3. The system of claim 1, wherein the controller is aremote controller enabling a user to control a position of the valvewirelessly.
 4. The system of claim 1, wherein a diameter of the firstpipe is equal to a diameter of the second pipe.
 5. The system of claim1, wherein the valve is vacuum operated and further comprising a vacuumpump connected to the valve, wherein the controller is configured tocontrol an operation of a vacuum pump to cause the valve to transitionfrom the open position to the closed position.
 6. The system of claim 1,wherein an output of the second pipe is in fluid connection with thefirst pipe within the muffler body.
 7. A system, comprising: a mufflerbody, including: a first internal baffle, a second internal baffle,wherein the first internal baffle defines a first end volume between thefirst internal baffle and the muffler body, the second internal baffledefines a second end volume between the second internal baffle and themuffler body, and the first internal baffle and the second internalbaffle define a central volume between the first end volume and thesecond end volume, a first pipe defining a first flow path through themuffler body, wherein the first flow path is a non-muffled flow path, asecond pipe extending between the first internal baffle and the secondinternal baffle, a third pipe extending between the first internalbaffle and the second internal baffle, and a second flow path definedthrough the muffler body, wherein the second flow path extends throughthe second pipe, the first end volume, the third pipe, and the secondend volume, the second flow path is a muffled flow path and at least oneof the second pipe and the third pipe includes a plurality ofperforations configured to allow exhaust gasses flowing therethrough todisperse out of the at least one of the second pipe and the third pipeand into the central volume of the muffler body; a valve disposed in thefirst flow path, wherein when the valve is in an open position exhaustgases flow through the first flow path and when the valve is in a closedposition exhaust gases flow through the second flow path; and acontroller configured to selectively cause the valve to transition fromthe open position to the closed position.
 8. The system of claim 7,further comprising a fourth pipe extending between the first internalbaffle and the second internal baffle, wherein the second flow pathincludes the fourth pipe.
 9. The system of claim 7, further comprising abaffling material disposed in the central volume and outside the firstpipe, the second pipe, and the third pipe.
 10. The system of claim 7,wherein the first internal baffle includes perforations configured toallow exhaust gasses flowing through the first end volume to disperseout of the first end volume and into the central volume of the mufflerbody.
 11. The system of claim 10, wherein the second internal baffleincludes perforations configured to allow exhaust gasses flowing throughthe second end volume to disperse out of the second end volume and intothe central volume of the muffler body.
 12. The system of claim 7,wherein a diameter of the second pipe is from 70 percent to 80 percentof a diameter of the first pipe and a diameter of the third pipe is from30 percent to 50 percent of the diameter of the second pipe.
 13. Thesystem of claim 12, wherein a distance between the first internal baffleand the second internal baffle is between 120 percent and 140 percent ofthe diameter of the first pipe.
 14. The system of claim 7, wherein thevalve is vacuum operated and further comprising a vacuum pump connectedto the valve, wherein the controller is configured to control anoperation of a vacuum pump to cause the valve to transition from theopen position to the closed position.
 15. A muffler, comprising: amuffler body; a first internal baffle disposed within the muffler body;a second internal baffle disposed within the muffler body, wherein thefirst internal baffle defines a first end volume between the firstinternal baffle and the muffler body, the second internal baffle definesa second end volume between the second internal baffle and the mufflerbody, and the first internal baffle and the second internal baffledefine a central volume between the first end volume and the second endvolume; a first pipe defining a first flow path through the mufflerbody, wherein the first flow path is a non-muffled flow path; a secondpipe extending between the first internal baffle and the second internalbaffle; a third pipe extending between the first internal baffle and thesecond internal baffle; and a second flow path defined through themuffler body, wherein the second flow path extends through the secondpipe, the first end volume, the third pipe, and the second end volume,the second flow path is a muffled flow path and at least one of thesecond pipe and the third pipe includes a plurality of perforationsconfigured to allow exhaust gasses flowing therethrough to disperse outof the at least one of the second pipe and the third pipe and into thecentral volume of the muffler body.
 16. The muffler of claim 15, furthercomprising a fourth pipe extending between the first internal baffle andthe second internal baffle, wherein the second flow path includes thefourth pipe.
 17. The muffler of claim 15, further comprising a bafflingmaterial disposed in the central volume and outside the first pipe, thesecond pipe, and the third pipe.
 18. The muffler of claim 15, whereinthe first internal baffle includes perforations configured to allowexhaust gasses flowing through the first end volume to disperse out ofthe first end volume and into the central volume of the muffler body.19. The muffler of claim 18, wherein the second internal baffle includesperforations configured to allow exhaust gasses flowing through thesecond end volume to disperse out of the second end volume and into thecentral volume of the muffler body.
 20. The muffler of claim 15, whereina diameter of the second pipe is from 70 percent to 80 percent of adiameter of the first pipe and a diameter of the third pipe is from 30percent to 50 percent of the diameter of the second pipe.